Ford Ranger Mazda Drifter 1999 Overhaul Manual Supplement – Engine, Transmission & Transfer Repair PDF

Description

Ford Ranger Mazda Drifter Overhaul Manual Supplement F161-20-99A

This is the January 1999 overhaul supplement issued by Ford/Mazda Motor Company for the Ranger and Drifter series. It is a bench-rebuild document, not a general owner’s handbook: the pages deal with stripping engines to the bare block, inspecting journals and bores against wear limits, re-shimming gear trains, pressing bearings on and off, and torquing every fastener back to specification. The supplement is applicable to vehicles from the VIN break points listed in its identification section, and it covers both UK/European spec and general spec left- and right-hand-drive builds.

Because this Ford Ranger Mazda Drifter overhaul manual supplement concentrates on the hard mechanical work, it fits the technician who already has the vehicle apart and needs the numbers, sequences and special tool references to put it back together correctly.

File Details

• Manual type: Overhaul / rebuild supplement
• Publisher: Ford/Mazda Motor Company
• Document number: F161-20-99A
• Edition date: January 1999
• Language: English
• Page count: 118 pages
• File format: PDF
• Printed in: Japan

Chapters Covered

• General Information
  • How to use this manual, range of topics, servicing procedure, symbols and advisory messages
  • Text sequence, units, conversion to SI units, rounding off, upper and lower limits
  • Fundamental procedures: preparation of tools and measuring equipment, special service tools
  • Disassembly, inspection during removal, arrangement of parts, cleaning of parts
  • Reassembly, adjustment, rubber parts and tubing, hose clamps, torque formulas, vise
  • Electrical system, connectors, new standards, abbreviations
• Engine — WL, WL Turbo
  • Engine overhaul service warning, engine mounting/dismounting
  • Engine disassembly/assembly, timing belt disassembly/assembly
  • Cylinder head disassembly/assembly (I), (II)
  • Cylinder block disassembly/assembly (I), (II), (III)
  • Engine inspection/repair, cylinder head inspection/repair, valve inspection
  • Valve guide inspection and replacement, valve seat inspection/repair, valve spring inspection
  • Camshaft inspection, camshaft oil clearance inspection, camshaft end play inspection
  • Cylinder block inspection/repair, oil jet valve and nozzle inspection
  • Piston inspection, piston clearance inspection/repair, piston ring clearance inspection
  • Piston pin clearance inspection, crankshaft inspection
  • Crankshaft oil clearance inspection/repair, crankshaft end play inspection/repair
  • Connecting rod inspection, connecting rod oil clearance inspection/repair
  • Connecting rod side clearance inspection, piston and connecting rod inspection
  • Balance shaft inspection (WL Turbo), bolt inspection, tensioner spring inspection
  • Valve clearance inspection, gear clearance inspection, plunger spring inspection
• Engine — F2
  • Full overhaul service content for the F2 diesel engine
• Engine — G6
  • Full overhaul service content for the G6 engine
• Manual Transmission — M15M-D, M15MX-D
  • Precaution, clutch housing, extension housing and transfer case disassembly/assembly
  • 5th/reverse gear and housing parts disassembly/assembly
  • Transmission case components disassembly/assembly
  • Mainshaft and countershaft components disassembly/assembly
  • Manual transmission inspection
• Manual Transmission — R15M-D, R15MX-D
  • Precaution, clutch housing, extension housing and transfer case disassembly/assembly
  • 5th/reverse gear and housing parts disassembly/assembly
  • Transmission case components disassembly/assembly
  • Mainshaft and countershaft components disassembly/assembly
  • Manual transmission inspection
• Transfer
  • Precaution, transfer component disassembly
  • Front drive sprocket bearing service
  • Output shaft component disassembly/assembly
  • Transfer component assembly, transfer inspection
  • Hub sleeve and shift fork inspection
• Technical Data
  • Engine specifications (WL, WL Turbo, F2, G6)
  • Manual transmission specifications (M15M-D, M15MX-D, R15M-D, R15MX-D)
  • Transfer specifications
• Special Tools
  • Engine special tools
  • Transmission special tools
  • Transfer box special tools
  • Front differential special tools
  • Remote free wheel (4×4) special tools
  • Front axle, rear axle, steering, brakes, suspension, air conditioning and general special tools

Read as a whole, this Ford Ranger Mazda Drifter overhaul manual supplement is a complete teardown-and-rebuild reference for the diesel and petrol drivetrains fitted to these vehicles. The supplement does not waste pages on routine servicing that any competent mechanic can do by looking at the vehicle — it exists for the jobs where clearances, press fits, shim selection, staged bolt tightening and torque-turn sequences decide whether the assembly survives. Engine chapters walk through the timing belt, cylinder head, cylinder block, pistons, rings, pins, crankshaft, connecting rods and balance shaft, with measurement points and wear limits spelled out in both metric and imperial units. Transmission chapters break the M15 and R15 families down to individual synchroniser rings, clutch hubs, shift rods, interlock pins and selective-fit C-washers, and the transfer chapter covers chain, sprockets, hub sleeves and shift forks for the 4×4 drivetrain.

What This Manual Lets You Do

The list of jobs this document supports is long, and it covers both the 2WD and 4×4 versions of the Ranger and Drifter. Owners and workshops use it for:

IMAGES PREVIEW

• Removing and remounting the engine on a stand with the correct hanger and SST set
• Replacing the timing belt and setting tensioner deflection to the printed figure
• Pulling the cylinder head, checking distortion, and re-torquing the head bolts through the correct staged turn sequence
• Inspecting and replacing valve guides and valve seats with the right cutters
• Checking camshaft runout, lobe height, journal diameters, oil clearance and end play
• Measuring cylinder bore wear and deciding between rebore and oversize pistons
• Checking piston-to-cylinder clearance, ring end gap and ring land clearance
• Verifying piston pin clearance and connecting rod small-end fit
• Checking crankshaft runout, main journal and crankpin diameters, and selecting the correct undersize bearing
• Measuring main journal and crankpin oil clearance with Plastigage
• Setting crankshaft end play with the correct thrust bearing
• Inspecting connecting rods for bend and twist, and checking bolt stretch length
• Overhauling the WL Turbo balance shaft and setting end play
• Adjusting valve clearance on a cold engine with the correct feeler gauge range
• Stripping and rebuilding the M15M-D, M15MX-D, R15M-D and R15MX-D manual transmissions
• Selecting the correct C-washers, thrust lock washers and adjustment shims from the sizes listed
• Installing shift rods and interlock pins in the correct order
• Setting synchroniser ring clearance and inspecting the 2nd synchroniser inner cone, double cone and ring
• Removing and pressing on mainshaft, countershaft and centre bearings with the specified SSTs
• Disassembling and reassembling the transfer case, chain, sprockets and shift mechanism
• Measuring and correcting output shaft and front drive sprocket bearing clearance with adjustment shims
• Checking hub sleeve to shift fork clearance on both transmission and transfer

Why the Correct Numbers Matter

Rebuild work on these drivetrains fails for predictable reasons: a head bolt that was not taken through its full turn sequence, a bearing pressed on without the right shim, a synchroniser ring past its wear limit, a crankshaft installed with the wrong undersize shell. This Ford Ranger Mazda Drifter overhaul manual supplement removes that guesswork. Every clearance, wear limit, tightening torque and selective-fit component thickness is printed in the technical data chapter and repeated at the relevant procedure, so the measurement you take on the bench can be compared directly against the value the factory specified.

The special tools chapter is equally important — the document lists the Mazda and Ford tool numbers for pulling bearings, installing seals, compressing valve springs, holding flywheels and aligning clutch plates, so you can either source the correct tool or identify a workable equivalent before you start.

Instant PDF Delivery

This Ranger Drifter overhaul manual supplement is supplied as a downloadable PDF. There is no shipping, no waiting for a paper copy, and no risk of a used workshop book arriving with pages missing. After payment the file is available immediately, and it can be read on a laptop, tablet or phone in the workshop, or printed page by page for the job in front of you. Whether you are rebuilding a single WL Turbo or running a workshop that sees Ranger and Drifter drivetrains regularly, the correct procedures and specifications are in your hands straight away.